1. Saving Energy Improving Technology Voith Paper Fiber & Environmental Solutions Ravensburg / Germany Eugen Loderer TAPPSA Conference Cape Town 23rd Sept. 2010

2. Voith Paper Fiber & Environmental Solutions Ravensburg / Germany Contacts South Africa: Hennie Alberts Tel: Cell:

3. Products for Saving Energy and Improving Technology: 1. Pulper 2
Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

4. IntensaPulper IP-V (Virgin) Pulper for Virgin Fiber
title, author short name | xx | 4

5. 1. How can energy be saved? - Avoid flow losses!
Excentricity instead of flow resistant directional baffles
Conventional
IntensaPulper IP
Durchmischung ist wichtig! Partikel müssen zum Rotor gebracht werden, das kann eine Konzentrische Strömung nicht, ein Partikel würde sich dauerhaft im Kreis bewegen. Umlenkung der Strömung mit Strömungsbrecher zur Pulpermitte kostet Energie. Es entstehen Wirbel.
PB: Avoid unnecessary turbulence Siehe auch Folie Farbtestbeweis.
title, author short name | xx | 5

6. 1. How can energy be saved? - Avoid flow losses!- Color test
5 sec
10 sec
15 sec
Conventionel
Intensa
Pulper
links ist der Pulper mit 4 Baffles ausgestattet, rechts ist die Auflösegarnitur exzentrisch ohne Baffle.
Bei 6% SD wird in aufgelöstem Zellstoff in die Mitte Tinte hinzugegeben.
Filme sep anhängen. bzw beide filme in ein flash
Erkenntnis: Durchmischung in der IPV Variante ist schneller. IPV ist schon durchgehend blau, im anderen sind die Einflüsse der Baffles deutlich zu sehen.
Mixing by excentricity, instead of baffles
title, author short name | xx | 6

7. Investigate your savings!
stellvertreted für IP V
mit verstellen der Schieber kann die individuelle Situation gezeigt werden.
Investigate your savings!
title, author short name | xx | 7

8. Intensa Technology - Rebuild
- A Chance for any Pulper
Intensa Technology - Rebuild
Low Energy Consumption in Pulping

9. Intensa Pulper Rebuild - Deflector and other components create a very good vortex and the suspension is guided to the center

10. Modifications by INTENSA components for existing pulpers③
Bale Breaker
②**
Intensa Deflector ④
Double Cone
Bottom
(option only) ①
Rotor Modification
**2 = to guide suspension and to improve vertical movement of suspension down to rotor
title, author short name | xx | 10

11. Projects at a Glance Customer in Thailand
Pulper type
UP10
Furnish
AOCC and LOCC
Tonnage
404 bdmt/day
Operation
Continuous
Operation volume
38 m3
Installed power
710 kW
Power consumption
590 kW in average
Consistency
3,5%
Scope of supply:
Intensa Deflector
Rotor Modification
Rotor cap with Eddy Cross
Installation on site
Startup supervision
Measurement before and after rebuild
title, author short name | xx | 11

12. Results of rebuild-ROI calculation Customer in Thailand
Before
After
Power consumption
590 kW
Consistency
3,5%
4,6%
Capacity
404 t
548 t
Net volume
38 m3
Specific energy input
15,5 kW/m3
Specific energy consumption
35,1 kWh/t
25,9 kWh/t
Cost saving per year
(with 350 days per year)
€/year
No change
31% increased
34% increased
No change
No change
26% of savings
ROI ≈ 13 months
title, author short name | xx | 12

13. Products for Saving Energy and Improving Technology: 1. Pulper 2
Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

14. Energy savings with Eclipse ...replaces step rotor
Outlook in Screening
Energy savings with Eclipse
...replaces step rotor

15. Eclipse Rotor: Energy saver for DIP applications Head to head trials: Current Step Rotor vs. Eclipse Rotor
Low energy Rotor to keep the current
performance of Step Rotor
Step Rotor
Eclipse Rotor
12.5 mm Gap
5 mm Gap
title, author short name | xx | 15

16. Eclipse Rotor: Energy saver for DIP applications Head to head trials: Current Step Rotor vs. Eclipse Rotor
Development of Power Consumption vs. Rotor Tip Speed
up to minus 30% power
consumption (kW)
at 20% higher
throughput level for
Eclipse Rotor
Power consumption [kW]
Rotor tip speed [m/s]
title, author short name | xx | 16

17. Development of Spec. Energy vs. Rotor Tip Speed
Eclipse Rotor: Energy saver for DIP applications Head to head trials: Current Step Rotor vs. Eclipse Rotor
Development of Spec. Energy vs. Rotor Tip Speed
up to minus 45%
specific energy
at 20% higher
throughput level for
Eclipse Rotor
Spec. energy [kWh/t]
Rotor tip speed [m/s]
title, author short name | xx | 17

18. Eclipse Rotor: Energy saver for DIP applications
Eclipse Performance
Higher throughput performance up to 20%
Specific energy reduced up to 45%
Similar thickening factor for both Rotor types
Up to 30% higher screening efficency
Operational recommendation
For rebuild and new installation instead Step Rotor
Rotor tip speed 18 to 20 m/s
Stock consistency 2,0 to 4.5 %
Rotor-Screen Basket gap 5 mm
Basket combination: All hole types
title, author short name | xx | 18

19. Products for Saving Energy and Improving Technology: 1. Pulper 2
Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

20. Guangzhou DIP 2 retrofit in 2005
rotor and screen basket situation before and afterwards
reduction of power consumption
increasing of sticky removal efficiency

21. Rotor Situation Ahlström Screen F4 before and after upgrade
Rotor Situation before upgrade
Rotor Situation after upgrade
title, author short name | xx | 21

22. Old Screen Basket and New C-bar Screen Basket
New C-bar Screen Basket with much
higher open area
Screen Basket old
title, author short name | xx | 22

23. Reduction ofPower Consumption in First Stage:
Situation before upgrade: Installed power: x 132 kW
rotor speed: rpm power consumption: 2 x 110 kW
Situation after upgrade: Installed power: x 132 kW rotor speed: rpm power consumption: 2 x 80 kW
Annual savings in energy at 350 running days a year:
kWH / 0,07 €/kWh = ,-- €/year
title, author short name | xx | 23

24. Sticky removal efficiency before upgrade:
1st Stage:
ηSticky 60%
title, author short name | xx | 24

25. 1st Stage: ηSticky 74% Sticky removal efficiency after upgrade:
title, author short name | xx | 25

26. The High Capacity Screen Basket for Stock Preparation
C-bar™ Q
The High Capacity Screen Basket
for Stock Preparation

27. C-barTM Q Profile width [mm] Relative open area [%] C-barTM S 3.3 100
2.7
~120
length unit
length unit
Standard bar
C-barTM S
Narrow bar
C-barTM Q
(previous SQ)
More bars at given length  higher number of slots  higher open area
title, author short name | xx | 27

28. C-barTM Q – Results of mill tests: Influence on sticky removal10 20 30 40 50 60 70 80 90
100 1
1,2
1,4
1,6
1,8 2
Slot velocity [m/s]
Sticky efficiency [%]
C-barTM Q
C-barTM S
Sticky efficiency at same slot velocity seems to be same with C-barTM S and Q
Sticky efficiency is better with lower slot velocity
B&P
DIP
title, author short name | xx | 28

29. C-bar™ Q Baskets - Summary
Increased Production with same slot size – C-bar™ Q provides up to 20% more capacity than C-bar S basket
Improved Quality – Higher screening efficiency at low slot velocities
NDura material assures basket strength and lifetime (add. we offer chromium layser)
Basket Wear Measurement Tool – repeatable method for measuring basket wear over time – developed by Voith – value added
“C-bar™ Q just one part of Voith‘s “ screening toolbox“
title, author short name | xx | 29

30. C-bar™ / MF Rotor Combination
Best screening efficiency / sticky and dirt removal
title, author short name | xx | 30

31. C-bar™ / MF Rotor Combination
title, author short name | xx | 31

32. Products for Saving Energy and Improving Technology: 1. Pulper 2
Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

33. HW-Cleaner HCL5 – I and EcoMizer Technology

34. Technical Data HCL5-I: Size HCL5-I Max admissible operation pressure
4 bar
Max admissible operation temperature
70°C
Pressure drop: Inlet  Outlet
1.5 – 2.0 bar
Inlet flow range
380 – 470 l/min
Min required accept pressure
0.1 bar
Dilution water flow
30 – 60 l/min
Max Inlet stock consistency
≤ 3 %
Schematic of the HCL5-I
title, author short name | xx | 34

35. HW cleaner HCL5-I with EcoMizer Technology Customer’s benefits
EcoMizer feature for the HCL5 allows: Minimum number of cleaners. Minimum number of stages.
Hydraulically optimized head design for maximum production and efficiency.
High concentration of contaminants in the reject Minimum fiber losses.
Fine cleaning at consistencies up to 3 % without reduced operational reliability.
Transparent reject chamber easy inspection of reject flow.
title, author short name | xx | 35

36. EcoMizer™ Technology Principle
Back-flushing of fibers to the accept
Specific adjustment of reject consistency possible
Flow on cone wall remains unchanged
So reduction of reject without affecting separation efficiency
title, author short name | xx | 36

37. EcoMizer™ Technology Influence on sand separation
Fiber losses [%] 90 94 92 98 96
100 10 15 20 5 25 30 35
Sand removal [%]
conventional cleaner (without back-flushing water)
cleaner with tangential water injection
EcoMizer™ Cleaner
title, author short name | xx | 37

38. Rebuild to EcoMizer technology Example: Stock prep Newsprint – A500T -1-
246 68
17e 4e 1e 26 8
not needed anymore
existing cleaner
rebuild to EcoMizer™
Inlet
Accept
Before
Energy
1.040 kW
Fibre losses
3,67 t/d
Reject
6,6 45% ash
7-stage
cascade
Energy
Fibre losses € €
Savings
€ /year
After
Energy
945 kW
Fibre losses
1,2 t/d
Reject
4,3 72% ash
5-stage
cascade
1st step
fibre loss reduction
title, author short name | xx | 38

39. Products for Saving Energy and Improving Technology: 1. Pulper 2
Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

40. LowEnergyFlotation 50% Energy Savings
EcoCell
LowEnergyFlotation
50% Energy Savings

41. LowEnergyFlotation The most efficient flotation concept, which saves up to 50% of energy
Target:
Reduction on energy consumption compared to standard applications by up to 50% at same quality demands.
How:
Modification of injector technology
Optimized injector hydrodynamics
Optimized EcoCell hydrodynamics
High efficiency pumps
title, author short name | xx | 41

42. Products for Saving Energy and Improving Technology: 1. Pulper 2
Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

43. Refining with PLURALIS – optimize your CEL
title, author short name | xx | 43

44. PLURALIS – Advantages of a new concept
Small bars & optimized grooves = more same diameter
More bars = more cutting edge length (CEL)
More CEL = lower SEL = lower refining intensity possible
Energy savings against standard designs = 10 – 20 % possible
Specific edge load
[J/m] =
Net refining power [kW]
Cutting edge length [km/s]
Refining intensity
title, author short name | xx | 44

45. lower Energy @ same Technology
PLURALIS design = reduction of specific edge load SEL by increase of CEL b b g
b = bar width
g = groove width
more CEL g
lower same Technology
title, author short name | xx | 45

46. Advantages by using Pluralis fillings
save Energy = COST SAVINGS
boost Quality = TECHNOLOGY 50 20 40 60 80
100
200
300
Total spec. energy [kWh/t]
Tensile index [Nm/g] 40
Freeness [SR] 30 20 10
100
200
300
Total spec. energy [kWh/t]
I would like to show as an example the influence of the cutting angle on the fibre treatment of southern pine kraft pulp.
Left hand side the development of drainage vs. energy is shown, right hand side you can see the development of tensile index vs. drainage.
The drainage increase at the beginning very slow while the strength develop its values very quick. Higher drainage rates requires less energy but increase the strength not so quick.
Using 60° instead of the 20° more energy is required. For example 25 % more energy results in 15% more strength.
To save energy a small angle would be helpful
Lets have a look to the other fillings parameter 
Fillings type
Spec. edge load
Pluralis
1 J/m
Common
Bleached Brazil Eucalypt pulp
title, author short name | xx | 46

47. title, author short name | 2007-08-xx | 47